TechDogs-"Buckle Up, As Tesla Is Secretly Driving Innovation In The Automotive Industry!"

Manufacturing Technology

Buckle Up, As Tesla Is Secretly Driving Innovation In The Automotive Industry!

By TD NewsDesk

TD NewsDesk

Updated on Fri, Sep 15, 2023

Overall Rating
Tesla is on the brink of a groundbreaking manufacturing innovation that could potentially halve production costs and accelerate Elon Musk's vision of producing millions of affordable Electric Vehicles in the coming decade.

According to a report, Tesla is closing in on a technology enabling the die-casting of almost the entire complex underbody of an EV in one seamless piece, as opposed to the conventional assembly of around 400 parts. #TeslasMoveToTeslafyTheFuture

Let's learn in detail what this technology is all about:
  • This technological leap builds on Tesla's pioneering use of colossal presses, exerting between 6,000 to 9,000 tons of clamping pressure, to mold its Model Y's front and rear structures in a process known as "gigacasting." This groundbreaking method dramatically cut production costs, leaving competitors scrambling to catch up.

  • The same report says this innovation's crux is central to Tesla's "unboxed" manufacturing strategy, which CEO Musk unveiled in March. The core concept involves producing substantial car sub-assemblies concurrently and assembling them swiftly.

That's cool but how will this move drive the automotive industry?
  • Terry Woychowski, President of U.S. engineering firm Caresoft Global, describes this development as "an enabler on steroids" with profound implications for the automotive industry. He emphasizes the difficulty of casting such large and intricate components and highlights how this could disrupt traditional car design and manufacturing processes.

  • Notably, the report suggests that Tesla's undisclosed design and manufacturing techniques could potentially allow the company to develop a car from scratch within an astonishing 18 to 24 months, a timeframe that stands in stark contrast to the three to four years typically required by competitors.

Now comes the critical question, why is Tesla developing this new approach?
  • The report says that Tesla's breakthrough centers on the design and mass production of enormous molds and their ability to integrate hollow subframes with internal ribs, reducing weight and enhancing safety. These innovations, developed by specialists across the globe in the UK, Germany, Japan and the United States, leverage 3D printing and industrial sand.

  • According to the report, the "gigacast dilemma," which has deterred automakers from producing ever-larger structures due to cost and risk factors, is being tackled head-on by Tesla's innovative approach. These monumental molds, some reaching 1.5 meters squared or more, are essential for improving efficiency.

  • Traditionally, the subframes in a car's underbody were produced by stamping and welding multiple components, leaving gaps. The same report highlights, however, that Tesla's vision involves casting subframes with hollow spaces in a single gigacasting. It is achieved by placing solid sand cores, produced through binder jets, within the overall mold. After casting, the sand cores are removed, creating the desired voids.

As Tesla pushes the boundaries of EV manufacturing, the automotive landscape is poised for a dramatic transformation. The implications of Tesla's technological prowess extend far beyond the assembly line, as it opens new possibilities for designing and producing EVs with unparalleled efficiency, affordability and safety.

Do you think with this innovation, the electric vehicle sector is primed to become even more competitive?

You can park your thoughts in the comments section below!

First published on Fri, Sep 15, 2023

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